Customized Shoe Textures And Shoe Portions

ABSTRACT

A shoe with a three-dimensional (3-D) surface texture created using rapid manufacturing techniques is provided. A plurality of 3-D surface texture options is presented on a user interface; each of the options is associated with one of a plurality of 3-D surface textures to be applied to a portion of a shoe. A selection of a 3-D surface texture is received and is used in part to generate a design file. The design file is used to instruct a rapid manufacturing device to manufacture the portion of the shoe comprised of the 3-D surface texture using a rapid manufacturing technique.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application having attorney docket number CNVR.236035 and entitled“Customized Shoe Textures and Shoe Portions,” is a ContinuationApplication of co-pending U.S. application Ser. No. 13/656,998, entitled“Customized Shoe Textures and Shoe Portions,” and filed Oct. 22, 2012.The entirety of the aforementioned application is incorporated byreference herein.

BACKGROUND

The manufacturing of shoes is typically a labor intensive andinefficient process that often leaves the consumer with little chance ofcustomizing the shoe according the consumer's personal taste orfunctional needs. Additionally, shoes have generally been manufacturedusing conventional materials that may not be optimal for the individualrequirements of the consumer.

SUMMARY

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter.

At a high level, the present invention is directed toward a shoe withcustomized three-dimensional (3-D) textures and customized 3-Dfunctional shoe portions created using rapid manufacturing techniques. Auser is able to select from a variety of 3-D surface texture optionscorresponding to 3-D surface textures, and the user is able to selectfrom a variety of 3-D functional portion options corresponding to 3-Dfunctional shoe portions. The selected 3-D surface texture(s) and/orfunctional portion(s) may be applied to different areas of the shoeusing a rapid manufacturing device. The result is a shoe with acustomized appearance and structure—an appearance and structure thatmeet the functional and aesthetic needs of the user.

Accordingly, in one aspect the present invention is directed to acomputerized method carried out by a computer running on a processor forcreating a 3-D surface texture on at least a first portion of a shoeusing rapid manufacturing techniques. The method comprises presenting aplurality of 3-D surface texture options on a user interface; each ofthe plurality of 3-D surface texture options is associated with one of aplurality of 3-D surface textures configured to be applied to the atleast the first portion of the shoe. A selection of a first 3-D surfacetexture option is received; the first 3-D surface texture option isassociated with a first 3-D surface texture. An augmented design file isgenerated based at least on a 3-D shoe design data file and the first3-D surface texture file. The augmented data file is used to instruct arapid manufacturing device to manufacture the first portion of the shoecomprised of the first 3-D surface texture using a rapid manufacturingtechnique.

In another aspect, the present invention is directed to a computerizedmethod carried out by a computer running on a processor for creating athree-dimensional (3-D) portion of a shoe having a first type offunctional property using rapid manufacturing techniques. The methodcomprises presenting a plurality of 3-D functional portion options on auser interface; each of the plurality of 3-D functional portion optionsis associated with one of a plurality of 3-D functional portions to beapplied to at least an area of a shoe configuration. A selection of atleast one 3-D functional portion is received. The at least one 3-Dfunctional portion option is associated with a first 3-D functionalportion. A data file is created based at least on the shoe configurationand the first 3-D functional portion. Using the data file, a rapidmanufacturing device is instructed to manufacture at least the first 3-Dfunctional portion of the shoe configuration.

In yet another aspect, the present invention is directed to acomputerized method carried out by a computer running on a processor formanufacturing a shoe upper with a customized 3-D exterior surfacetexture. The method comprises presenting a plurality of 3-D surfacetexture options on a user interface; each of the plurality of 3-Dsurface texture options is associated with one of a plurality of 3-Dsurface textures to be applied to at least a portion of a first shoeupper configuration. A selection of at least one 3-D surface textureoption is received; the at least one 3-D surface texture option isassociated with a first 3-D surface texture. A data file is createdbased at least on the first shoe upper configuration and the selected atleast one 3-D surface texture. The data file is used to instruct a lasersintering device to manufacture the at least the portion of the firstshoe upper configuration comprised of the first 3-D surface texture.

BRIEF DESCRIPTION OF THE DRAWINGS

Examples are described in detail below with reference to the attacheddrawing figures, wherein:

FIG. 1 depicts a side view of an exemplary shoe for reference purposesin accordance with aspects of the present invention;

FIG. 2 depicts a flow diagram of an exemplary method of creating athree-dimensional surface texture on a shoe using rapid manufacturingtechniques in accordance with aspects of the present invention;

FIG. 3 depicts a flow diagram of an exemplary method of creating athree-dimensional surface texture on a shoe upper using a lasersintering device in accordance with aspects of the present invention;

FIG. 4 depicts a side perspective view of a shoe having an exemplary 3-Dsurface texture formed according to aspects of the present invention;

FIG. 5 depicts another side perspective view of a shoe having anexemplary 3-D surface texture formed according to aspects of the presentinvention;

FIG. 6 depicts a bottom perspective view of a shoe having an exemplary3-D surface texture formed according to aspects of the presentinvention;

FIG. 7 depicts an exemplary discrete portion of an upper formedaccording to aspects of the present invention;

FIG. 8 depicts an exemplary shoe having an exemplary 3-D surface textureformed according to aspects of the present invention;

FIG. 9 is a block diagram of an exemplary computing environment suitablefor use in implementing aspects of the present invention;

FIG. 10 depicts a flow diagram of an exemplary method of creating a 3-Dportion of a shoe having a first type of functional property using rapidmanufacturing techniques in accordance with aspects of the presentinvention;

FIG. 11 depicts a side perspective view of a shoe having an exemplary3-D functional forefoot flexibility portion formed according to aspectsof the present invention;

FIG. 12 depicts a cross-sectional view of a shoe taken along line 12-12of FIG. 1 illustrating a midsole of the shoe in a forefoot area of theshoe formed according to aspects of the present invention;

FIG. 13 depicts a cross-sectional view of a shoe taken along line 13-13of FIG. 1 illustrating an exemplary 3-D functional portion in a midfootarea of the shoe formed according to aspects of the present invention;and

FIG. 14 depicts an exemplary view of a shoe having an exemplary 3-Dfunctional heel lockdown portion and an exemplary 3-D functionalbreathability portion formed according to aspects of the presentinvention.

DETAILED DESCRIPTION

The subject matter of the present invention is described withspecificity herein to meet statutory requirements. However, thedescription itself is not intended to limit the scope of this patent.Rather, the inventors have contemplated that the claimed subject mattermight also be embodied in other ways, to include different steps orcombinations of steps similar to the ones described in this document, inconjunction with other present or future technologies. Moreover,although the terms “step” and/or “block” might be used herein to connotedifferent elements of methods employed, the terms should not beinterpreted as implying any particular order among or between varioussteps herein disclosed unless and except when the order of individualsteps is explicitly stated.

The present invention is directed toward a shoe with customizedthree-dimensional (3-D) textures and customized 3-D functional shoeportions created using rapid manufacturing techniques. A user is able toselect from a variety of 3-D surface texture options corresponding to3-D surface textures, and the user is able to select from a variety of3-D functional portion options corresponding to 3-D functional shoeportions. The selected 3-D surface texture(s) and/or functionalportion(s) may be applied to different areas of the shoe using a rapidmanufacturing device. The result is a shoe with a customized appearanceand structure—an appearance and structure that meet the functional andaesthetic needs of the user.

FIG. 1 depicts an exemplary shoe 100. The shoe 100 includes an upper 110and a sole structure 116. The sole structure, in turn, includes amidsole 112 and an outsole 114. For reference purposes, the shoe 100 maybe divided into three general regions or areas: a forefoot or toe region124, a midfoot region 126, and a heel region 128. The shoe 100 alsoincludes a lateral side 122 and a medial side (not shown). The lateralside 122 extends along a lateral side of a user's foot and generallyincludes the regions 124, 126, and 128. The medial side extends along amedial side of the user's foot and also includes the regions 124, 126,and 128. The lateral side 122, the medial side, and the regions 124,126, and 128 are not intended to demarcate specific areas of the shoe100. Instead, they are intended to represent general areas of the shoe100 and are used for reference purposes for the following discussion.For example, the medial side and the lateral side 122 may converge nearthe toe region 124 at respective sides of a toe box. Similarly, it iscontemplated that the medial side and the lateral side 122 may alsoconverge at respective sides of an Achilles reinforcement proximate theheel region 128. Therefore, depending on the shoe design andconstruction, the terms medial, lateral, toe, heel, and the likegenerally refer to a proximate location and may not be limiting.

FIG. 1 also depicts a line 12-12 bisecting the shoe 100 proximate theforefoot region 124. The line 12-12 represents a cutline used in thedepiction of FIG. 12, which is discussed hereinafter. FIG. 1additionally depicts a line 13-13 that bisects the shoe 100 proximatethe midfoot region 126. The line 13-13 represents a cutline used in thedepiction of FIG. 13, which is also discussed hereinafter.

The upper 110 is generally secured to the sole structure 116 and definesa cavity for receiving a foot. Access to the cavity is provided by anankle opening 118 located in the heel region 128. A lace 120 extendsthrough various apertures in the upper 110. The lace 120 may act toselectively increase or decrease the size of the ankle opening 118 andthe girth of the upper 110 as the lace 120 applies a pressure across aforefoot opening extending between the medial side and the lateral side122.

Various materials may be used to construct the upper 110. For example,the upper 110 may be constructed of a uniform sintered materialmanufactured using a rapid manufacturing technique. A uniform sinteredmaterial is not limited to a homogeneous material, but insteadcontemplates a composite-like material comprised of a number of discretematerials that when sintered, form a common material. Therefore, theterm uniform represents a resulting common material that is notintermixed with other non-commonly formed materials. This process willbe explained in greater depth below. The upper 110 may also beconstructed of a sintered material in combination with conventionalmaterials including leather, synthetic leather, rubber, textiles, mesh,polymer foams, and/or other traditional shoe-constructing materials. Theconventional materials and the sintered materials(s) may be stitched,adhesively bonded, or otherwise fused to each other.

The sole structure 116 may be integrally formed with the upper 110 orconstructed separately and secured to the upper 110. As mentioned above,the sole structure 116 comprises the outsole 114 and the midsole 112;however it is also contemplated that the sole structure 116 may be a cupsole, a sandal-like structure, or any combination of outsole, midsole,and insole. The outsole 114 forms a ground-engaging surface of the solestructure 116. The outsole 114 and/or the midsole 112 may be formed ofconventional materials such as rubber, leather, or a polymer foammaterial (polyurethane or ethylvinylacetate for example). Alternatively,the outsole 114 and/or the midsole 112 may be formed, in part or inwhole, of a uniform sintered material manufactured using a rapidmanufacturing technique. The outsole 114 may be integrally formed withthe midsole 112, or the outsole 114 may be attached to a lower surfaceof the midsole 112. Further, it is contemplated that the midsole 112 maybe inserted into a cavity within the outsole 114.

As a preface to the more detailed discussion below, a brief overview ofrapid manufacturing fabrication techniques will be provided. Rapidmanufacturing techniques may include laser sintering, stereolithography,solid deposition modeling, and the like. Rapid manufacturing techniquesinvolve creating a 3-D design in a data file, such as a Computer AidedDesign (CAD) file, and building the object of the 3-D design in anautomated layer-by-layer process. The rapid manufacturing equipment ordevice reads the 3-D design from the data file and lays down successivelayers of powder, liquid, or sheet material to build the 3-D object.Selected layers are joined together by the rapid manufacturing device,such as a sintering laser, to form the 3-D object of the design.

One example of a rapid manufacturing technique is laser sintering. Lasersintering involves creating a 3-D design in a data file, such as a CADfile. The laser sintering equipment reads/processes the CAD file andforms the 3-D object of the design, such as, for example, an upper orportion of an upper for a shoe, using a high-powered laser toselectively fuse powders or small particles of plastic, metal, polymer,ceramic, or glass powders. The laser selectively fuses materials byscanning cross-sections generated from the data file or scan data on thesurface of a material bed. After each cross-section is scanned andselected areas fused, the material bed is lowered by one layerthickness, and a new layer of material is applied on top. The process isrepeated until the 3-D object is complete. Material that is not fused issubsequently removed.

Turning now to FIG. 2, a flow diagram is depicted illustrating anexemplary method 200 for creating a 3-D surface texture on a portion ofa shoe (such as the shoe 100 of FIG. 1) using rapid manufacturingtechniques. The portion of the shoe may comprise a complete upper (suchas the upper 110 of FIG. 1), a complete midsole (such as the midsole 112of FIG. 1), or a complete outsole (such as the outsole 114 of FIG. 1).As well, the portion of the shoe may comprise a portion of the upper, aportion of the midsole, or a portion of the outsole. In addition, theportion of the shoe may comprise any combination of the upper, midsole,and outsole.

At a step 210, 3-D surface texture options are presented on a userinterface, such as a display monitor coupled with a computing device.The 3-D surface texture options are associated with a variety of 3-Dsurface textures that are configured to be applied to a portion of theshoe. The options may include product or identification codescorresponding to different 3-D surface textures, textual descriptions ofthe different 3-D surface textures, visual images of the differenttextures, auditory descriptions of the different textures, and the like.In one aspect, the 3-D surface texture options presented may depend onthe portion of the shoe to which the 3-D surface texture will beapplied. For example, some surface textures may be suitable for a toecap of a shoe, while other surface textures may be suitable for thebottom of an outsole.

The different types of 3-D surface textures are myriad. The textures mayinclude geometric shapes, leather-like textures, suede-like textures,grid-like textures, scale-like textures, plate-like textures, textual ornumerical elements, character elements, design elements, and the like.Additionally, users may customize their own 3-D surface texture. Forinstance, one of the 3-D surface texture options may enable a user toaccess a digital modeling tool to create a customized 3-D surfacetexture.

In one aspect, the 3-D surface texture options are presented after (orprior to) a scan of a foot of a user is performed. The scan may beperformed using known methods, computer systems, and software. The scanis performed to obtain various physical characteristics of the foot ofthe wearer in order to design a customized shoe that fits thespecifications and characteristics of the user's foot. From the scan, a3-D shoe design data file is created that integrates features specificto a scanned foot (e.g., arch support, width, and/or length) and may bestored in association with a data store.

At a step 212, a selection of a first 3-D surface texture option isreceived. The first 3-D surface texture option is associated with afirst 3-D surface texture to be applied to a portion of the shoe. In oneaspect, selections of additional 3-D surface texture optionscorresponding to other 3-D surface textures may also be received. Theother 3-D surface textures are configured to be applied to portions ofthe shoe as well. The first 3-D surface texture may be the same ordifferent from the other 3-D surface textures. As well, the portion ofthe shoe to which the other 3-D surface textures will be applied may bethe same or different as the portion of the shoe to which the first 3-Dsurface texture will be applied. By way of example, a user may select agrid-like surface texture to be applied to the toe region of the upperand a suede-like surface texture to be applied to the remaining portionof the upper of the shoe. In another example, a user may select areptilian-like texture to be applied to an upper of a shoe andadditionally select a design element (such as a snake) to be applied toa portion of the upper so that the snake appears to be resting on thereptilian-like texture. Therefore, it is contemplated that a user makesa selection of the 3-D surface texture option, which is then received bya system for applying an associated surface texture to a design file ofthe affected shoe portion.

At a step 214, an augmented design file is generated based at least onthe 3-D shoe design data file created subsequent to scanning the user'sfoot and the received selections of the 3-D surface textures. Further,it is contemplated that the scanning of a foot is optional and may notbe implemented in exemplary aspects. The 3-D shoe design data file mayalready be stored in association with a data store. Once the 3-D surfacetexture option is received, the 3-D shoe design data file is updated toreflect the 3-D surface texture to be applied to the portion of theshoe. The 3-D shoe design data file may be augmented multiple times asdifferent 3-D surface texture options are received. It is contemplatedthat the augmenting of the design data file includes applyingappropriate information and/or calls to information such that when arapid manufacturing process implements the design data file, theresulting object includes the selected texture(s) in a desired portion.

In one aspect, the 3-D shoe design data file is a generic file intendedto mass produce shoes of a certain size using rapid manufacturingtechniques. In other words, in some aspects, the 3-D shoe design datafile may not be specific to the characteristics of an individual user.The generic 3-D shoe design data file may still be augmented or modifiedupon receiving selections of one or more 3-D surface texture options(e.g., a factory employee may select one or more surface textures to beapplied to the shoe).

At a step 216, the augmented design file is used to instruct a rapidmanufacturing device to manufacture at least the portion(s) of the shoecomprised of one or more 3-D surface textures using a rapidmanufacturing technique. As mentioned above, rapid manufacturingtechniques may include laser sintering, stereolithography, soliddeposition modeling, and the like.

Using the augmented design file, for example, a layer of powder may bedispersed to form an initial layer of the portion being created.Additional layers of powder may be dispersed on top of the initial layerand a high-powered laser may be used to selectively fuse the layers ofpowdered material together to begin forming the portion of the shoe.Additional layers of powder are then added and selectively fused untilthe 3-D surface texture is created. The powder that is not fused iseventually removed. A powder-like material is used here for explanationpurposes, but, as previously discussed, any type of material iscontemplated.

In one aspect, the 3-D surface texture is created using colored powders.By way of illustrative example, an area of the upper (or midsole oroutsole) without a 3-D surface texture may be a first color, and theportion of the upper comprising the 3-D surface texture may be a secondcolor. Further, the user may be able to specify the color of the 3-Dsurface texture. Additionally different types of powders or materialsmay be used to impart different functional properties to the 3-D surfacetextures. For example, some powders when fused may form a more rigidmaterial as compared to other powders. Rigid-type powders may be used tocreate a 3-D surface texture in the heel region of an upper—an area thattypically needs more support.

The portion formed using the rapid manufacturing technique may be formedusing any known material suitable for use in rapid manufacturingprocesses and sufficiently flexible to form a somewhat flexible,bendable article. In some examples, the portion may be formed using athermoplastic elastomer, or other similar materials.

Turning now to FIG. 3, a flow diagram is depicted illustrating anexemplary method 300 of manufacturing a shoe upper with a customized 3-Dsurface texture. At a step 310, a plurality of 3-D surface textureoptions are presented on a user interface. The 3-D surface textureoptions are associated with a plurality of 3-D surface textures to beapplied to one or more portions of the shoe upper. In one aspect, the3-D surface texture options may be presented subsequent to orconcurrently with a plurality of shoe upper configuration options; theshoe upper configuration options are associated with a plurality of shoeupper configurations. In turn, shoe upper configurations may includesuch configurations as high-tops, mid-tops, low-tops, athletic(running-type uppers, water sport-type uppers, hiking-type uppers,etc.), casual, and the like.

In one aspect, the 3-D surface texture options may be dependent on thetype of shoe upper configuration selected. For instance, if a watersport-type upper is selected, the 3-D surface texture options maycomprise open-type (e.g., mesh-like, void-filled) textures that allowwater to easily drain from the shoe. By contrast, if a hiking sportupper is selected, the 3-D surface texture options may include solidtextures with areas of increased thickness to provide support anddurability.

At a step 312, a selection of at least one 3-D surface texture option isreceived. As well, a selection of a shoe upper configuration option mayalso be received. In one aspect, upon receiving selections of the 3-Dsurface texture option and/or the shoe upper configuration option, adigital representation of the shoe upper configuration with the 3-Dsurface texture applied is presented on a user interface. Thus, aconsumer at a point-of-sale could preview his or her shoe beforedeciding to purchase the shoe. In another example, a factory employeecould preview the upper with the applied 3-D surface texture beforebeginning mass production of a shoe.

At a step 314, a data file is created based at least on the shoe upperconfiguration and the selected 3-D surface texture. The data file ismodifiable. That is, additional data may be received concerning 3-Dsurface textures, the upper, or other parts of the shoe; the data filemay be updated based on the additional data.

At a step 316, the data file is used to instruct a laser sinteringdevice to manufacture the portion of the shoe upper configurationcomprising the selected 3-D surface texture using techniques asdescribed above. In one aspect, the data file is used to instruct thelaser sintering device to manufacture the entire shoe upperconfiguration. The shoe upper configuration may be manufactured in twoor more discrete portions that are subsequently joined together tocreate the shoe upper configuration. The different portions may bejoined together by stitching, adhesively bonding, or fusing. Further,different 3-D surface textures may be applied to the different discreteportions.

Turning to FIG. 10, a flow diagram is depicted illustrating an exemplarymethod 1000 for creating a 3-D portion of a shoe having a first type offunctional property using rapid manufacturing techniques. The 3-Dfunctional portion may comprise a flexible forefoot portion in theforefoot area (e.g., region 124 of FIG. 1) of the shoe, a heel lockdownportion in the heel area (e.g., region 128 of FIG. 1) of the shoe, amidfoot support portion in the midfoot area (e.g., region 126 of FIG. 1)of the shoe, and/or a breathability portion applied to areas of theupper, midsole, and/or outsole of the shoe. Additional functionalcharacteristics and locations are contemplated.

At a step 1010, a plurality of 3-D functional portion options arepresented on a user interface, such as a display monitor coupled with acomputing device. The 3-D functional portion options are associated withone or more 3-D functional portions that are configured to be applied toan area(s) of the shoe. The 3-D functional portion options may bepresented in conjunction with the 3-D surface texture options discussedabove. In one aspect, the 3-D surface texture options presented may bedependent on the 3-D functional portion options presented and viceversa. The functional portion options may include product oridentification codes corresponding to the different 3-D functionalportions, textual descriptions of the different 3-D functional portions,visual images of the different 3-D functional portions, auditorydescriptions of the different functional portions, and the like.

As mentioned, the different 3-D functional portions may include aforefoot flexibility portion configured to provide a user a greaterdegree of flexibility in the forefoot region of the shoe as compared toa traditional shoe, a midfoot support portion configured to providecustom support in the midfoot region of the shoe based on, for example,a scan of the user's foot, and a heel lockdown portion configured toprovide a greater degree of support or rigidity in the heel region ofthe shoe as compared to a traditional shoe. Further, a 3-D functionalportion may include a breathability portion applied to selected areas ofthe shoe. The breathability portion is configured to promote aircirculation and to allow water to freely exit the shoe.

In one aspect, the 3-D functional portion options are presented after(or prior to) a scan of a foot of a user is performed (if a custom footscan is utilized). The scan may be performed using known methods,computer systems, and software. The scan is performed to obtain variousphysical characteristics of the foot of the wearer in order to design acustomized shoe that fits the specifications and characteristics of theuser's foot. From the scan, a 3-D shoe design data file is created thatintegrates features specific to a scanned foot (e.g., arch support,width, and/or length) and may be stored in association with a datastore. While the foregoing exemplary method utilizes a custom scan of auser's foot, it is contemplated that one or more 3-D functional portionsmay be selected and integrated into/with a non-scan-generated shoedesign data file, in another exemplary aspect discussed hereinafter.

At a step 1012, a selection of at least one 3-D functional portionoption is received. Selections of 3-D surface texture option(s) may alsobe received at step 1012. The selected 3-D functional portion option isassociated with a first 3-D functional portion to be applied to an areaof the shoe. In one aspect, selections of additional 3-D functionalportion options corresponding to other 3-D functional portions may bereceived. These additional 3-D functional portions may be applied to asame area of the shoe as the first 3-D functional portion or to adifferent area of the shoe as the first 3-D functional portion. Upon asystem receiving a 3-D functional portion option, the system applies theassociated functional portion to a design file of the affected shoearea. Therefore, it is contemplated, in an exemplary aspect, that anytype of function portion may be combined at any location(s).

At a step 1014, a data file is created based at least on the shoeconfiguration data file created subsequent to scanning the user's footand the received selection(s) of the 3-D functional portion(s). It iscontemplated that the scanning of the foot is optional and may not beimplemented in exemplary aspects. The 3-D shoe design data file mayalready be stored in association with a data store. Once the 3-Dfunctional portion option is received, the 3-D shoe design data file isupdated to reflect the 3-D functional portion to be applied to the areaof the shoe. The 3-D shoe design data file may be augmented multipletimes as different 3-D functional portion options are received. Further,the 3-D shoe design data file may be augmented or updated based on anyreceived 3-D surface texture options. It is contemplated that theaugmenting of the design data file includes applying appropriateinformation and/or calls to information such that when a rapidmanufacturing process implements the design data file, the resultingobject includes the selected functional portion(s) in the appropriatearea of the shoe.

In one aspect, the 3-D shoe design data file is a generic file intendedto mass produce shoes of a certain size using rapid manufacturingtechniques. In other words, in some aspects, the 3-D shoe design datafile may not be specific to the characteristics of an individual user.The generic 3-D shoe design data file may still be augmented or modifiedupon receiving selections of one or more 3-D functional portion options(e.g., a factory employee may select one or more functional portions tobe applied to the shoe).

At a step 1016, the data file is used to instruct a rapid manufacturingdevice to manufacture at least the area(s) of the shoe comprised of oneor more of the 3-D functional portions using a rapid manufacturingtechnique such as laser sintering, sterolithography, solid depositionmodeling, and the like. As well, the data file may be used to instruct arapid manufacturing device to manufacture areas of the shoe comprised ofone or more 3-D surface textures. Further, the 3-D surface textures maybe applied to the one or more 3-D functional portions. For instance, auser may select a heel lockdown functional portion to be applied to anupper portion of the shoe in the heel area. The user may further selecta 3-D surface texture to be applied to the heel lockdown functionalportion. Any and all such variations are contemplated as being withinthe scope of the invention.

In one aspect, the 3-D functional property is created using differenttypes of powders or materials to impart the different types offunctional properties. For example, rigid-type powders (or othermaterials) may be used to create the midfoot support portion or the heellockdown portion of the shoe, while more flexible-type powders may beused to create the forefoot flexibility portion or the breathabilityportion of the shoe. In another aspect, the 3-D functional property iscreated by using different wall thickness or textures to impart thedifferent types of functional properties. This will be explained ingreater depth below.

FIGS. 4-8 depict some examples of 3-D surface textures created using themethods outlined in FIGS. 2 and 3. FIG. 4 depicts a side perspectiveview of a shoe 400. The shoe 400 comprises an upper 410 and a solecomplex 416 (comprised of an outsole and a midsole). The shoe 400 alsoincludes a 3-D surface texture 412. The 3-D surface texture 412 is atextual element that is applied to portions of the sole complex 416 andthe upper 410 using rapid manufacturing techniques. A user may be ableto customize the textual elements. For instance, the textual elementsmay be the user's name or a brand. As well, the textual elements may bea different color than other parts of the shoe 400. The upper 410 andthe sole complex 416 may all be integrally formed together using rapidmanufacturing techniques. Further, it is contemplated that the 3-Dsurface texture 412 is integrally formed with either the upper 410 orthe sole complex 416 prior to joining the respective other portion.

FIG. 5 depicts a shoe 500 having a sole complex 516 and an upper 510.The upper 510 may be formed using rapid manufacturing techniques whilethe sole complex 516 may be formed using conventional techniques. Theupper 510 is then attached to the sole complex 516 via bonding, fusing,lasting, strobel, etc. Conversely, both the upper 510 and the solecomplex 516 may be integrally formed together using rapid manufacturingtechniques. The upper 510 is manufactured with a 3-D surface texture512. In this case, the 3-D surface texture 512 comprises a weave-liketexture having interconnected ridges and valleys forming the weave-likepattern.

FIG. 6 depicts a bottom view of a shoe 600. An outsole 614 is shown witha 3-D surface texture 612. The outsole 614 and the 3-D surface texture612 may be formed using rapid manufacturing techniques. The 3-D surfacetexture 612 has areas of increased (e.g., offset) and decreased (e.g.,inset/recessed) thickness that not only create aesthetic appeal, butalso produce interesting footprints when a user is walking on sand orother conforming surfaces. Additionally, the 3-D surface texture appliedto a ground-contacting surface of the sole allows for customized treadpatterns and locations. The 3-D surface texture 612 may include areashaving a first color 615 and areas having a second color 617.

FIG. 7 depicts a discrete portion 700 of a shoe upper 710. The upper 710is comprised of a uniform sintered material made using rapidmanufacturing techniques. The upper 710 includes areas having a firstthickness 713 extending between an interior surface (not shown) and anexterior surface (a surface onto which the 3-D surface texture isvisible in FIG. 7). The upper 710 also includes areas having a secondthickness 715 extending between the interior surface and the exteriorsurface. In combination, these areas produce a 3-D surface texture 712.The upper 710 also includes a plurality of eyelet holes 720 that areintegrally formed from and within the uniform sintered material as theyextend between the interior surface and the exterior surface.

The portion 700 may be joined with additional portions to form acomplete shoe. For instance, the portion 700 may be joined with amirror-image upper portion to form a complete (or near complete) upper.As well, the portion 700 may be joined with a sole complex to form ashoe. The portion 700 may be joined with other portions throughstitching, adhesively bonding, fusing, and the like. The other portionsto which the portion 700 is joined may comprise uniform sinteredmaterials or conventional materials (leather, vinyl, rubbers, etc.).

FIG. 8 depicts a shoe 800 comprised of an upper portion 810 having a 3-Dsurface texture 812 on an exterior surface and formed using rapidmanufacturing techniques. The upper portion 810 includes a series ofintegrally formed eyelet holes 820. The shoe 800 also includes a solecomplex 816 comprised of a midsole 813 and an outsole 814. The midsole813 and/or the outsole 814 may be formed using rapid manufacturingtechniques, or, alternatively, the midsole 813 and/or outsole 814 may beformed using conventional materials.

The upper portion 810 is joined to a second mirror-image upper portion(not shown) to help complete the upper. The second upper portion mayhave the same 3-D surface texture as the upper portion 810, or the 3-Dsurface texture may be different. As shown, additional materials such asrubber, leather, and fabric may be used to complete the upper. The upperportion 810 may overlay a fabric portion 815 so that the fabric portion815 rests against the wearer's foot. In this example, the fabric portion815 is visible through the exterior surface of the upper 810 by way ofone or more apertures formed in the upper. Therefore, it is contemplatedthat an interior surface of an upper may contact an interior liner(e.g., sock liner) or other functional and aesthetic-enhancingmaterials.

FIGS. 11-14 depict some examples of 3-D functional portions createdusing the exemplary method 1000 outlined in FIG. 10, in accordance withaspects of the present invention. FIG. 11 depicts a side perspectiveview of a shoe 1100, in accordance with an aspect of the presentinvention. The shoe 1100 comprises an upper 1112, and a sole complex1116. The shoe 1100 further comprises a forefoot flexibility portion1110. The forefoot flexibility portion 1110 is applied to a forefootarea of the shoe 1100 and is configured to provide a greater degree offlexibility to this region as compared to shoes manufactured without theforefoot flexibility portion 1110. Increased forefoot flexibility maybenefit wearers such as rock climbers, runners, hikers, and the like.

In one aspect, the forefoot flexibility portion 1110 is created bygenerating, using rapid manufacturing techniques, a shoe wall in a shoeupper portion in the forefoot area that has a thickness that is lessthan the thickness of a shoe wall in the forefoot area of a shoemanufactured without the forefoot flexibility portion. Exemplarythicknesses may include thicknesses between 0.5 mm and 5 mm. Flexibilitymay further be increased in the forefoot flexibility portion 1110 bycreating a grid-like texture in the forefoot area as shown in FIG. 11.The grid-like texture comprises a framework of crisscrossing members andopen areas. The grid-like texture may be configured such that the openareas have dimensions of approximately 5 mm×5 mm, 10 mm×10 mm, 15 mm×15mm, 20 mm×20 mm, 5 mm×10 mm, 10 mm×15 mm, 5 mm×20 mm, or anycombination/dimension in between. Larger open areas contribute to theflexibility of the forefoot flexibility portion 1110. Additionally, theforefoot flexibility portion 1110 may be created or augmented (usingrapid manufacturing techniques) by reducing the thickness of the solecomplex 1116 in the forefoot area as compared to the thickness of a solecomplex in the forefoot area of a shoe manufactured without the forefootflexibility portion. The thickness of the sole complex may be reduced byreducing the thickness of the midsole, the outsole, and/or both themidsole and the outsole.

FIGS. 12-13 depict cross-sectional views of the shoe 100 of FIG. 1 andillustrate forefoot and a midfoot support functional portionsrespectively, in accordance with aspects of the present invention. FIG.12 is a cross-sectional view taken along line 12-12 of FIG. 1, whileFIG. 13 depicts a cross-sectional view taken along line 13-13 of FIG. 1.FIG. 12 includes an upper 1210, a midsole 1212, an outsole 1214, and asole complex 1216 comprised of the midsole 1212 and the outsole 1214.Since FIG. 12 is a cross-sectional view taken from the forefoot regionof the shoe 100, the midsole 1212 is fairly thin to improve flexibilityin the forefoot region, in this exemplary aspect.

The cross-sectional view of FIG. 13 is taken from the midfoot region ofthe shoe 100. FIG. 13 includes an upper 1310, a midfoot support portion1312, an outsole 1314, and a sole complex 1316 comprised of the midfootsupport portion 1312 and the outsole 1314. The thickness of the midfootsupport portion 1312 is greater than the thickness of the midsole 1212.Further, the midfoot support portion 1312 has a thickness greater than amidsole thickness of a shoe manufactured without the midfoot supportportion 1312. Increased thickness in this area provides support to themidfoot area of the foot. It is contemplated that the midfoot supportportion 1312 may have portions of varying thickness along the shoe'swidth to create a customized midsole based on a scan of the user's foot.

The midfoot support portion 1312 is manufactured, using rapidmanufacturing techniques, by generating a first thickness of a shoe soleportion in the midfoot area of the shoe that is greater than a secondthickness associated with the shoe configuration without the midfootsupport portion.

FIG. 14 depicts a shoe 1400 comprising a breathability function portion1410, and a sole complex 1416. The shoe 1400 further comprises a heellockdown functional portion 1412 in the heel area of the upper of theshoe 1400. The heel lockdown portion 1412 is configured to provide extrasupport and/or rigidity to the heel area of the user's foot. The heellockdown portion 1412 may be generated, using rapid manufacturingtechniques, by creating a grid-like texture in an upper portion of theshoe in the heel area. The grid-like texture comprises a framework ofcrisscrossing members and open areas. The crisscrossing members of thegrid-like texture may have a predetermined thickness that is greaterthan a thickness associated with a shoe without the heel lockdownfunctional portion 1412. Exemplary thicknesses may include thicknessesbetween 4 and 10 mm. The heel lockdown portion 1412 may also begenerated, using rapid manufacturing techniques, by creating a solidwall in an upper portion of the shoe 1400 in the heel area having apredetermined thickness that is greater than a thickness associated witha shoe without the heel lockdown functional portion 1412. Exemplarythicknesses include thicknesses between 4 and 10 mm.

The breathability functional portion 1410 is applied to, for example,the shoe upper in the forefoot and midfoot region of the shoe 1400. Thebreathability functional portion 1410 may be manufactured, using rapidmanufacturing techniques, by creating a grid-like texture in an upperportion of the shoe 1400. The grid-like texture is comprised ofcrisscrossing members and open areas. The crisscrossing members maycomprise solid bars, tubular structures, and the like. The breathabilityfunctional portion 1410 is configured to increase air exchange betweenthe outside environment and the interior of the shoe 1400 and also tolet any water within the shoe 1400 to easily escape.

Although FIG. 14 depicts the breathability functional portion 1410applied to substantially all of the upper portion in the forefoot andmidfoot area of the shoe 1400, it is contemplated that the breathabilityfunctional portion 1410 may be applied to more discrete areas in theupper portion of the forefoot area, the midfoot area, and/or the heelarea of the shoe 1400. The breathability functional portion 1410 mayoverlay a fabric portion so that the fabric portion rests against thewearer's foot. The fabric portion, in turn, may be comprised of materialthat further increases the breathability aspects of the breathabilityfunctional portion 1410. In another aspect, a fabric underlay is notutilized, and the breathability functional portion 1410 rests againstthe wearer's foot.

An exemplary computing environment suitable for use in implementingaspects of the present invention is described below in order to providea general context for various aspects of the present invention.Referring to FIG. 9, such an exemplary computing environment is shownand designated generally as computing device 900. The computing device900 is but one example of a suitable computing environment and is notintended to suggest any limitation as to the scope of use orfunctionality of embodiments of the invention. Neither should thecomputing device 900 be interpreted as having any dependency orrequirement relating to any one or combination of componentsillustrated.

Embodiments of the invention may be described in the general context ofcomputer code or machine-useable instructions, includingcomputer-executable instructions such as program modules, being executedby a computer or other machine, such as a personal data assistant orother handheld device. Generally, program modules, including routines,programs, objects, components, data structures, etc., refer to code thatperforms particular tasks or implements particular abstract data types.Embodiments of the invention may be practiced in a variety of systemconfigurations, including hand-held devices, consumer electronics,general-purpose computers, more specialty computing devices, and thelike. Embodiments of the invention may also be practiced in distributedcomputing environments where tasks are performed by remote-processingdevices that are linked through a communications network.

With continued reference to FIG. 9, the computing device 900 includes abus 910 that directly or indirectly couples the following devices: amemory 912, one or more processors 914, one or more presentationcomponents 916, one or more input/output (I/O) ports 918, I/O components920, and an illustrative power supply 922. The bus 910 represents whatmay be one or more busses (such as an address bus, data bus, orcombination thereof). Although the various blocks of FIG. 9 are shownwith lines for the sake of clarity, in reality, delineating variouscomponents is not so clear, and metaphorically, the lines would moreaccurately be grey and fuzzy. For example, one may consider apresentation component such as a display device to be an I/O component.Additionally, many processors have memory. The inventors hereofrecognize that such is the nature of the art, and reiterate that thediagram of FIG. 9 is merely illustrative of an exemplary computingdevice that can be used in connection with one or more embodiments ofthe present invention. Distinction is not made between such categoriesas “workstation,” “server,” “laptop,” “hand-held device,” etc., as allare contemplated within the scope of FIG. 9 and reference to “computer”or “computing device.”

The computing device 900 typically includes a variety ofcomputer-readable media. Computer-readable media may be any availablemedia that is accessible by the computing device 900 and includes bothvolatile and nonvolatile media, removable and non-removable media.Computer-readable media comprises computer storage media andcommunication media. Computer storage media includes volatile andnonvolatile, removable and non-removable media implemented in any methodor technology for storage of information such as computer-readableinstructions, data structures, program modules or other data. Computerstorage media includes, but is not limited to, RAM, ROM, EEPROM, flashmemory or other memory technology, CD-ROM, digital versatile disks (DVD)or other optical disk storage, magnetic cassettes, magnetic tape,magnetic disk storage or other magnetic storage devices, or any othermedium which can be used to store the desired information and which canbe accessed by computing device 900. Communication media, on the otherhand, embodies computer-readable instructions, data structures, programmodules or other data in transport mechanism and includes anyinformation delivery media.

The memory 912 includes computer-storage media in the form of volatileand/or nonvolatile memory. The memory may be removable, non-removable,or a combination thereof. Exemplary hardware devices include solid-statememory, hard drives, optical-disc drives, and the like. The computingdevice 900 includes one or more processors that read data from variousentities such as the memory 912 or the I/O components 920. Thepresentation component(s) 916 present data indications to a user orother device. Exemplary presentation components include a displaydevice, speaker, printing component, vibrating component, and the like.

The I/O ports 918 allow the computing device 900 to be logically coupledto other devices including the I/O components 920, some of which may bebuilt in. Illustrative components include a microphone, joystick, gamepad, satellite dish, scanner, printer, wireless device, etc.

Aspects of the subject matter described herein may be described in thegeneral context of computer-executable instructions, such as programmodules, being executed by a mobile device. Generally, program modulesinclude routines, programs, objects, components, data structures, and soforth, which perform particular tasks or implement particular abstractdata types. Aspects of the subject matter described herein may also bepracticed in distributed computing environments where tasks areperformed by remote processing devices that are linked through acommunications network. In a distributed computing environment, programmodules may be located in both local and remote computer storage mediaincluding memory storage devices.

Furthermore, although the term “server” is often used herein, it will berecognized that this term may also encompass a search engine, a Webbrowser, a set of one or more processes distributed on one or morecomputers, one or more stand-alone storage devices, a set of one or moreother computing or storage devices, a combination of one or more of theabove, and the like.

The present invention has been described in relation to particularexamples, which are intended in all respects to be illustrative ratherthan restrictive. Alternative embodiments will become apparent to thoseof ordinary skill in the art to which the present invention pertainswithout departing from its scope. Certain features and subcombinationsare of utility and may be employed without reference to other featuresand subcombinations and are contemplated within the scope of the claims.

What is claimed is:
 1. A computerized method for creating athree-dimensional (3-D) portion of a shoe having a first type offunctional property using rapid manufacturing techniques, thecomputerized method carried out by a processor running on a computer,and comprising: presenting a plurality of 3-D functional portion optionson a user interface device, each of the plurality of 3-D functionalportion options representing one of a plurality of 3-D functionalportions to be applied to a portion of a shoe; receiving from an inputdevice a user selection of at least one 3-D functional portion option ofthe plurality of 3-D functional portion options, the at least one 3-Dfunctional portion option representing a first 3-D functional portioncomprising a forefoot flexibility portion configured to provideflexibility in a forefoot area of the portion of the shoe; creating,using the processor, a data file corresponding to the portion of theshoe and the forefoot flexibility portion; storing the data file ascomputer-readable instructions at a non-transitory data storage mediumof the computer; and using the data file to instruct a rapidmanufacturing device to manufacture at least the forefoot flexibilityportion of the portion of the shoe.
 2. The method of claim 1, whereinmanufacturing the forefoot flexibility portion comprises: forming a shoewall in a shoe upper portion in the forefoot area of the portion of theshoe having a first thickness that is less than a second thickness ofthe portion of the shoe in the forefoot area without the forefootflexibility portion; and forming a grid-like texture in the forefootarea comprising a framework of crisscrossing members and open areas, theopen area having predetermined dimensions.
 3. The computerized method ofclaim 1, wherein the rapid manufacturing device includes at least one ofa laser sintering device, a solid deposition modeling device, or astereolithography device.
 4. The computerized method of claim 1, whereina plurality of 3-D surface texture options are further presented on theuser interface device.
 5. The computerized method of claim 4, whereinthe plurality of 3-D surface texture options presented is predeterminedbased upon the plurality of 3-D functional portion options presented. 6.The computerized method of claim 4, wherein the plurality of 3-Dfunctional portion options presented is predetermined based upon theplurality of 3-D surface texture options presented.
 7. A computerizedmethod for creating a three-dimensional (3-D) portion of a shoe having afirst type of functional property using rapid manufacturing techniques,the computerized method carried out by a processor running on acomputer, and comprising: presenting a plurality of 3-D functionalportion options on a user interface device, each of the plurality of 3-Dfunctional portion options representing one of a plurality of 3-Dfunctional portions to be applied to a portion of a shoe; receiving froman input device a user selection of at least one 3-D functional portionoption of the plurality of 3-D functional portion options, the at leastone 3-D functional portion option representing a first 3-D functionalportion comprising a heel lockdown portion configured to provide supportand rigidity in a heel area of the portion of the shoe; creating, usingthe processor, a data file corresponding to the portion of the shoe andthe heel lockdown portion; storing the data file as computer-readableinstructions at a non-transitory data storage medium of the computer;and using the data file to instruct a rapid manufacturing device tomanufacture at least the heel lockdown portion of the portion of theshoe.
 8. The method of claim 7, wherein manufacturing the heel lockdownportion comprises forming a grid-like texture on a shoe upper portion inthe heel area of the portion of the shoe, the grid-like texture having apredetermined thickness that is greater than a second thickness of theportion of the shoe in the heel area without the heel lockdown portion.9. The computerized method of claim 7, wherein the rapid manufacturingdevice includes at least one of a laser sintering device, a soliddeposition modeling device, or a stereolithography device.
 10. Thecomputerized method of claim 7, wherein a plurality of 3-D surfacetexture options are further presented on the user interface device. 11.The computerized method of claim 10, wherein the plurality of 3-Dsurface texture options presented is predetermined based upon theplurality of 3-D functional portion options presented.
 12. Thecomputerized method of claim 10, wherein the plurality of 3-D functionalportion options presented is predetermined upon the plurality of 3-Dsurface texture options presented.
 13. The computerized method of claim7, wherein the data file further corresponds to a scan of a user's foot.14. A computerized method for creating a three-dimensional (3-D) portionof a shoe having a first type of functional property using rapidmanufacturing techniques, the computerized method carried out by aprocessor running on a computer, and comprising: presenting a pluralityof 3-D functional portion options on a user interface device, each ofthe plurality of 3-D functional portion options representing one of aplurality of 3-D functional portions to be applied to a portion of ashoe; receiving from an input device a user selection of at least one3-D functional portion option of the plurality of 3-D functional portionoptions, the at least one 3-D functional portion option representing afirst 3-D functional portion comprising a breathability portionconfigured to increase air exchange between an interior and an exteriorof the shoe; creating, using the processor, a data file corresponding tothe portion of the shoe and the breathability portion; storing the datafile as computer-readable instructions at a non-transitory data storagemedium of the computer; and using the data file to instruct a rapidmanufacturing device to manufacture at least the breathability portionof the portion of the shoe.
 15. The method of claim 14, whereinmanufacturing the breathability portion comprises forming a grid-liketexture in a shoe upper portion of the portion of the shoe, thegrid-like texture comprising a framework of solid crisscrossing membersand open areas.
 16. The computerized method of claim 14, wherein therapid manufacturing device includes at least one of a laser sinteringdevice, a solid deposition modeling device, or a stereolithographydevice.
 17. The computerized method of claim 14, wherein a plurality of3-D surface texture options are further presented on the user interfacedevice.
 18. The computerized method of claim 17, wherein the pluralityof 3-D surface texture options presented is predetermined based upon theplurality of 3-D functional portion options presented.
 19. Thecomputerized method of claim 17, wherein the plurality of 3-D functionalportion options presented is predetermined based upon the plurality of3-D surface texture options presented.
 20. The computerized method ofclaim 14, wherein the data file further corresponds to a scan of auser's foot.